Fiber-Containing Lid With High Polymer Mating Region

ABSTRACT

A lid for a container having an upper rim bead, the lid having a fiber-containing body and a mating portion depending from the body that is configured to mate with the upper rim bead, wherein the mating portion has a higher weight percentage of a polymer than the body. The mating portion can include the polymer on a medial or lateral surface, and/or inside the mating portion, or the mating portion can be entirely made of polymer.

PRIORITY CLAIM

This application claims priority to U.S. provisional application Ser. No. 62/850,312 filed May 20, 2019, and EPO1907921.9 filed Jun. 4, 2019.

FIELD OF THE INVENTION

The field of the invention is lids for drinking cups.

BACKGROUND

The following description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

Many people enjoy having coffee, tea, or other beverages, and it is well known to imbibe such drinks from a disposable paper cup. Such cups are typically consturcted from paper having a thin inner plastic coating. One example is shown in U.S. Pat. No. 6,926,197 B2. Such cups can also be made entierely of plastic, but paper is more environmentally friendly than plastic.

U.S. Pat. No. 6,926,197 B2 and all other referenced extrinsic materials are incorporated herein by reference in their entirety. Where a definition or use of a term in a reference that is incorporated by reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein is deemed to be controlling.

The U.S. Pat. No. 6,926,197 patent, and all other extrinsic materials discussed herein are incorporated by reference in their entirety. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

Paper-based cups have several disadvantages. For example, paper tends to absorb liquid, resulting in deformation of the cup. Wax-coated paper cups are advantageous in that they tend to resist deformation, however, their popularity diminished because wax can melt with hot liquids, and wax coatings tend to be too thick.

It is well known to make paper coffee cups with very thin plastic coatings. For example, US20070170236A1 teaches a cup made of a plastic-coated paper. Such cups provide several advantages. First, the plastic does not melt. Second, the plastic protects paper-based cups from liquid exposure.

Regarding lids, it is known in some instances to use a paper lid for a paper container. For example, U.S. Pat. No. 1,952,401 teaches a paper lid for an ice cream container. This paper lid is satisfactory for its intended purpose, but would not work well for a paper coffee cup because it provides an inadequate seal. A lid for the coffee cup must be closed tightly to provide a secure seal, because liquid would press against the lid when a person tilts the cup for drinking. A paper lid for an ice cream container works sufficiently well because one does not normally tilt the ice cream container with its lid attached. And also ice cream is solid, not liquid. A second reason that a paper lid is dysfunctional for a coffee cup is that as the lid absorbs liquid, even to a small extent, such absorption might well weaken the lid sufficiently to negatively impact the seal. For these and probably other reasons, the vast majority of lids for paper drinking cups are made entirely of plastic.

U.S. Pat. No. 4,589,569 teaches a plastic lid. Such lids work well with typical paper drinking cups, but are unsatisfactory with respect to environmental effects. Plastic pollution is currently one of the greatest environmental concerns, harming all manner of plants, oceans, animals, and humans. It can take hundreds or even thousands of years for plastic to break down, so the damage to the environment is long-lasting. It has been reported that about 16 billion plastic lids are used on disposable coffee cups each year. The European Union is moving forward on banning single-use plastic stirrers and plates by 2021. It is time for us to seriously consider how to reduce the amount of single-use plastic and maintain our environment clean and safe.

The basic problem is that “the perfect is the enemy of the good”. People keep trying to make a lid that is entirely fibrous material, i.e., with no plastic whatsoever. That may happen in the future, but in the meantime an awful lot of plastic is thrown away in plastic lids. What is needed right now is lid that made mostly of paper or other fiber-based material, but has sufficient plastic to provide an adequate seal for a coffee cup or other paper (or mostly paper) container.

SUMMARY OF THE INVENTION

The inventive subject matter provides apparatus, systems, and methods in which a paper or other fiber-based lid has a plastic-reinforced mating portion that creates a seal with a corresponding cup.

Contemplated lids include a body, and a polymer-containing mating portion that extends circumferentially and downwardly from the body. There is an extra coating of polymer in or on the mating portion, or the mating portion can be entirely constructed of the polymer.

The lid preferably contains no more than 10 wt % of polymer material. In preferred embodiments, the lid has no more than 5 wt % polymer, and in especially preferred embodiments, the lid has no more than 1 wt % polymer.

The mating portion has a mating portion and a flared portion. The mating portion of the lid refers to the portion that is sized and dimensioned to mate with an upper rim bead of a cup. The mating portion preferably has an annular indentation with a depth of at least 0.5 mm, more preferably at least 1.0 mm, and most preferably at least 1.5 mm. The flared portion is sized and dimensioned to assist a user in positioning the lid onto the top upper rim bead of a cup.

The mating portion is reinforced by one or more additional layers of polymer material, which provides additional stiffness. The polymer layer is at least 0.1 mm thick. In preferred embodiments, the polymer layer is at least 0.2 mm thick and more preferred embodiments, at least 0.3 mm thick. The polymer layer can be applied medial, lateral, or any combination thereof, onto the fiber-containing layer of the lid, or it is disposed inside of the fiber-containing layer.

The polymer material includes polyethylene, polydiketoenamine, polypropylene, polyetylene terephthalate, high-density polyethylene, polyvinyl chloride, low-density polyethylene, ultra-high-molecular-weight polyethylene and any combination thereof.

The body can have a drinking hole disposed of the raised portion in the centrally depressed body. A polymer coating is disposed on an upper surface of the body, about at least a portion of the drinking hole. The polymer coating of the body extends at least 5 mm away from the drinking hole. In some embodiments, the polymer coating can be also applied to the underside of the body.

As used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously.

As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a lid.

FIG. 2 is a cross-sectional view of the lid of FIG. 1, and a container.

FIG. 3 is a cross-sectional view of the lid of FIG. 1.

FIG. 4 is a cross-sectional view of an alternative embodiment of a lid.

FIG. 5 is a cross-sectional view of another alternative embodiment of a lid.

FIG. 6 is a cross-sectional view of another alternative embodiment of a lid.

FIG. 7 is a cross-sectional view of lid with a magnetic upper rim bead.

DETAILED DESCRIPTION

The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.

The present invention relates to apparatus, methods, and systems for a fiber-containing lid having a polymer coated reinforced region, which provides a secure seal to a liquid container. In preferred embodiments, the reinforced region is a mating portion of the mating portion of the lid. The principles and operations for such methods and systems, according to the present invention, may be better understood with reference to the accompanying description and drawings.

FIG. 1 generally depicts a fiber-containing lid 100 at least having a body 110 and a mating portion 122 that depends from the body 110. The lid 100 comprises at least two materials, a fibrous material and a polymer coating.

All suitable fibrous materials are contemplated, including wood and vegetable fibers (as for example utilized in papers and cardboards). Biodegradable paper is especially preferred to reduce negative environmental impact when the lids are disposed.

All suitable polymer materials are contemplated, especially including polymers typically used to coat inside surface of paper coffee cups. This includes polyethylene, polypropylene, polyetylene terephthalate, high-density polyetylene, polyvinyl chloride, low-density polyetylene, ultra-high-molecular-weight polyethylene, and any combination thereof.

To reduce the environmental impact, preferred embodiments of lid 100 have no more than 10 wt % the total polymer material(s). In some embodiments, the lid has no more than 10 wt % or even 5 wt % polymer, and the most preferred embodiments have no more than 1 wt % polymer.

The body 110 has a drinking hole 130. It is contemplated that a polymer coating can be disposed on an upper surface of the lid, about at least a region 140 adjacent the drinking hole 130. A coating in that region coating can provide an improved mouth feel relative to embodiments where the region is not coated. In some embodiments, the polymer coating of the body extends at least 5 mm around the drinking hole 130.

FIG. 2 depicts the side view of lid 200. The lid 200 is configured to be removably coupled with a cup 250, allowing repeated closing and opening the lid. The body 210 can have a raised portion 211 that surrounds a concavity 212. The raised portion can be of constant height, or of varying heights. Typically, the drinking hole is positioned in the raised portion 211.

The body 210 would typically have an underside with a polymer coating 213, although there are embodiments in which there is no underside coating. Thus, it is contemplated that the reinforcing polymner could be applied only to the mating portion 222. It is also contemplated that the body 210, or even the entire lid, can be coated on the outer surfaces (not shown). The body 210 has an angled portion 221 can flare slightly from a top of the lid 200, and the flared region can extend to meet with the mating portion 222.

The mating portion 220 extends circumferentially and downwardly from the body 210. The mating region 222 is sized and dimensioned to securely mate with the upper rim bead 251 of the cup 250. For a typical paper coffee cup, the mating portion would preferably have an indentation with a depth of at least 1.5 mm. Having a secure seal is desirable because it protects the user from spilling of hot liquid such as coffee, tea, and soup over himself or herself.

The mating portion 220 can itself have a flared region 223, sized and dimensioned to assist a user in positioning the lid onto the top upper rim bead of a cup, thereby helping to prevent significant deformation of the lid 200.

FIG. 3 shows a cross-sectional view of the lid of FIG. 1, including a body 321 and a mating portion 320. There is a polymer coating 305 on the underside of the body 321. The mating portion 320 includes an indented region 322 and a flared region 323. There is an extra coating 324 of polymer on part of the medial side of the body 321, and the medial sides of the indented 322 and flared 323 regions.

FIG. 4 shows a cross-sectional view of an alternative lid, including a body 421 and a mating portion 420. There is a polymer coating 405 on the underside of the body 421. The mating portion 420 includes an indented region 422 and a flared region 423. There is an extra coating 425 of polymer on the lateral side of the indented region 422.

FIG. 5 shows a cross-sectional view of another alternative lid, including a body 521 and a mating portion 520. There is a polymer coating 505 on the underside of the body 521. The mating portion 520 includes an indented region 522 and a flared region 523. There is an extra coating 526 of polymer on both medial and lateral sides of the indented region 522.

FIG. 6 shows a cross-sectional view oft another alternative lid, including a body 621 and a mating portion 620. There is a polymer coating 605 on the underside of the body 621. The mating portion 620 includes an indented region 622 and a flared region 623. There is an extra stiffening member 627 on inside of the indented region 622. In some embodiments stiffening member 627 comprises a stiff polymer.

It is also contemplated that one could use magnetic coupling so that the cup and lid would “click” together, magnetically, and thereby remain “mated” without the need for any mechanical coupling as in FIG. 2. To that end, in FIG. 7 is similar to FIG. 2, except that the upper rim bead 251 is magnetic, and the stiffening member 627A is a metal or other material attracted by magnetic force.

As indicated above, the polymer coatings on the undersides of the various lids 205, 305, 405, 505, and 605 is distinctly preferably, but could nevertheless be omitted depending on the composition of the lid. Thus, the polymer coatings on some or all of the portions of the undersides of the various lids 205, 305, 405, 505, and 605 should be viewed as optional.

There are at least two reasons for adding the polymer material to the mating portions of the various embodiments. First, if the polymer is disposed on a medial side of the mating portion, the polymner can protect the mating portion from deformation caused by the liquid or a vapor evaporating from the liquid. Second, including a polymer in the mating portion can significantly enhance stiffness of the mating portion, thereby providing a secure seal with a cup or other vessel.

Where the polymer is included in the mating portion as one or more layers, the thickness at least one such layer is preferably at least 0.1 mm, more preferably at least 0.2 mm, and most preferably at least 0.3 mm.

It is also contemplated that the mating portion could be entirely polymeric, i.e., with no fibrous content. In such instances the polymeric mating portion could have a thin extension that extends up into the body of the lid, or is glued or otherwise adhered to a medial or lateral side of the body.

In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.

Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc. 

What is claimed is:
 1. A lid for a container having an upper rim bead, the lid comprising: a body comprising a first fibrous material; and a mating portion depending from the body, the mating portion comprising a second fibrous material, and having a recess configured to mate with the upper rim bead; wherein the mating portion has a higher weight percentage of a first polymer than the body.
 2. The lid of claim 1, wherein the mating portion comprises a medial layer of the first polymer, and a lateral layer of the second fibrous material.
 3. The lid of claim 1, wherein the first fibrous material of the body is continuous with the second fibrous material of the mating portion.
 4. The lid of claim 1, wherein the body has a layer of the first polymer.
 5. The lid of claim 1, wherein the mating portion has a second layer of the first polymer.
 6. The lid of claim 5, wherein the second layer comprises a second polymer that has a different chemical composition that the first layer.
 7. The lid of claim 1, wherein the body has a drinking hole, and a layer of a second polymer disposed about the drinking hole.
 8. The lid of claim 7, wherein the layer of the second polymer extends at least 5 mm around the drinking hole.
 9. The lid of claim 7, wherein the body has a raised portion disposed about a central depression, and the drinking hole is disposed in the raised portion.
 10. The lid of claim 1, wherein the lid has no more than 10 wt % of the first polymer.
 11. The lid of claim 1, wherein the lid has no more than 5 wt % of the first polymer.
 12. The lid of claim 1, wherein the lid has no more than 1 wt % of the first polymer.
 13. The lid of claim 2, wherein the medial layer is at least 0.1 mm thick.
 14. The lid of claim 2, wherein the medial layer is at least 0.3 mm thick.
 15. The lid of claim 2, wherein the mating portion flares outwardly to a bottom of the lid.
 16. The lid of claim 1, wherein the recess comprises an annular indentation having a depth of at least 1.5 mm.
 17. (canceled)
 18. The lid of claim 1, further comprising a second layer of the first polymer disposed within, or lateral to, the lateral layer of the second fibrous material.
 19. The lid of claim 1, wherein the first polymer comprises at least one of polyethylene and polydiketoenamine. 